Studio e sviluppo di tecniche per la produzione di nanocompositi a matrice di alluminio

Foundry aluminum alloys play a fundamental role in several industrial fields, as they are employed in the production of several components in a wide range of applications. Moreover, these alloys can be employed as matrix for the development of Metal Matrix Composites (MMC), whose reinforcing phases may have different composition, shape and dimension. Ceramic particle reinforced MMCs are particular interesting due to their isotropic properties and their high temperature resistance. For this kind of composites, usually, decreasing the size of the reinforcing phase leads to the increase of mechanical properties. For this reason, in the last 30 years, the research has developed micro-reinforced composites at first, characterized by low ductility, and more recently nano-reinforced ones (the so called metal matrix nanocomposite, MMNCs). The nanocomposites can be obtained through several production routes: they can be divided in in-situ techniques, where the reinforcing phase is generated during the composite production through appropriate chemical reactions, and ex situ techniques, where ceramic dispersoids are added to the matrix once already formed. The enhancement in mechanical properties of MMNCs is proved by several studies; nevertheless, it is necessary to address some issues related to each processing route, as the control of process parameters and the effort to obtain an effective dispersion of the nanoparticles in the matrix, which sometimes actually restrict the use of these materials at industrial level. In this work of thesis, a feasibility study and implementation of production processes for Aluminum and AlSi7Mg based-MMNCs was conducted. The attention was focused on the in-situ process of gas bubbling, with the aim to obtain an aluminum oxide reinforcing phase, generated by the chemical reaction between the molten matrix and industrial dry air injected in the melt. Moreover, for what concerns the ex-situ techniques, stir casting process was studied and applied to introduce alumina nanoparticles in the same matrix alloys. The obtained samples were characterized through optical and electronic microscopy, then by micro-hardness tests, in order to evaluate possible improvements in mechanical properties of the materials.

Influence of particle size, density and concentration on bend erosive wear in pneumatic conveyors

Particle concentration is a principal factor that affects erosion rate of solid surfaces under particle impact, such as pipe bends in pneumatic conveyors; it is well known that a reduction in the specific erosion rate occurs under high particle concentrations, a phenomenon referred to as the “shielding effect”. The cause of shielding is believed to be increased likelihood of inter-particulate collisions, the high collision probability between incoming and rebounding particles reducing the frequency and the severity of particle impacts on the target surface. In this study, the effects of particle concentration on erosion of a mild steel bend surface have been investigated in detail using three different particulate materials on an industrial scale pneumatic conveying test rig. The materials were studied so that two had the same particle density but very different particle size, whereas two had very similar particle size but very different particle density. Experimental results confirm the shielding effect due to high particle concentration and show that the particle density has a far more significant influence than the particle size, on the magnitude of the shielding effect. A new method of correcting for change in erosivity of the particles in repeated handling, to take this factor out of the data, has been established, and appears to be successful. Moreover, a novel empirical model of the shielding effects has been used, in term of erosion resistance which appears to decrease linearly when the particle concentration decreases. With the model it is possible to find the specific erosion rate when the particle concentration tends to zero, and conversely predict how the specific erosion rate changes at finite values of particle concentration; this is critical to enable component life to be predicted from erosion tester results, as the variation of the shielding effect with concentration is different in these two scenarios. In addition a previously unreported phenomenon has been recorded, of a particulate material whose erosivity has steadily increased during repeated impacts.